Replacing Old Duff Urethane flares

[Scott McKelvey]

So I have old Duff Urethane flares, stamped 1200.01. It looks like Duff is out of the Flare business. I’m really not interested in cutting more metal. I read through all the relevant Flare posts I could find, but most are pretty old too.

1. so I need to know what’s closest replacement, size+shape (I reached out to Duff's but haven't heard back yet)
2. in a perfect world, the holes would be the same, but I’m guessing that’s too much to ask for
3. and in a perfect/perfect world, they’d come in gloss black
4. Fiberglass is not an option for me b/c of flexibility

These seem to be the current non-XL sized fender flares. So what say ye?

1. ABS, textured https://www.dennis-carpenter.com/trucks/body/fenders/c6tz-9829164-pr-qtr-panel-fender-flares-black
2. Toms urethane ultraflex, gloss black but paintable (but these are the larger/new rear style) https://tomsoffroad.com/products/66...rs2NeFl0XZdM_WG-ibcKN8u9nqZkJzPAaAvNfEALw_wcB
3. Fiberglass https://www.wildhorses4x4.com/early-bronco-fiberglass-fender-flares
4. Warflares https://www.wildhorses4x4.com/gorilla-warflares-early-bronco-fender-flares
5. Jeff’s duraflex (are these the Bushwackers?)
6. Bushwacker, textured black, Dura flex https://www.jegs.com/i/Bushwacker-B...FF10t01kNTVq5gInf1zyESB_99vUezSgaAuTqEALw_wcB

 

[Scott McKelvey]

So, here's an interesting option that I decided to give a try. I did some reading and apparently there's alot of 90's highend cars that had polyurethane bumpers and what not. And apparently they can be "welded". You have to buy special PUR rod/filler, but otherwise a cheap plastic welding kit with just the iron (i bought the delux kit with staples and all types of stuff for $40), and a pack of rods were like $20 (I had to buy a big variety pack to get a handful of the PUR rods). So now i have a new Tool that i can use for whatever.

I have to say, I'm not unimpressed (one pic below, but i had to do 2 different repairs). other than burning myself multiple times on the medieval iron, it seems quite strong, and i probably did a terrible job prepping. I'm going to touch up with some gloss black paint and re-install. And i have a rear flare with a big split in it that I'm not going to do the same.

I'm also swapping the rivets for #6-32 Stainless 7/16" long truss head (slightly wider head than a normal buttonhead) with stainless nylocks. McMaster Carr was $22 for 100 count of each w/ shipping+tax.

 

[georgehirvela]

So I have old Duff Urethane flares, stamped 1200.01. It looks like Duff is out of the Flare business. I’m really not interested in cutting more metal. I read through all the relevant Flare posts I could find, but most are pretty old too.

1. so I need to know what’s closest replacement, size+shape (I reached out to Duff's but haven't heard back yet)
2. in a perfect world, the holes would be the same, but I’m guessing that’s too much to ask for
3. and in a perfect/perfect world, they’d come in gloss black
4. Fiberglass is not an option for me b/c of flexibility

These seem to be the current non-XL sized fender flares. So what say ye?

1. ABS, textured https://www.dennis-carpenter.com/trucks/body/fenders/c6tz-9829164-pr-qtr-panel-fender-flares-black
2. Toms urethane ultraflex, gloss black but paintable (but these are the larger/new rear style) https://tomsoffroad.com/products/66...rs2NeFl0XZdM_WG-ibcKN8u9nqZkJzPAaAvNfEALw_wcB
3. Fiberglass https://www.wildhorses4x4.com/early-bronco-fiberglass-fender-flares
4. Warflares https://www.wildhorses4x4.com/gorilla-warflares-early-bronco-fender-flares
5. Jeff’s duraflex (are these the Bushwackers?)
6. Bushwacker, textured black, Dura flex https://www.jegs.com/i/Bushwacker-B...FF10t01kNTVq5gInf1zyESB_99vUezSgaAuTqEALw_wcB

Guess I haven't bought flares in a long, long time. Pricey little fuckers...

 

[widowmaker77]

I think possibly the bushwhacker duraflex flares are the closest if not the same thing as those old flares from duffs.

 

[.94 OR]

I have used a similar plastic welder in the past. Seems like the difference between melt and burn are about 2°F and the plastic ends up burnt black. Hoping you have better luck.
I have used McMaster but recently had to order 700 tiny SS bolts and they were just too expensive. I used this outfit, but showing in a similar size to what you have.
https://boltsandnuts.com/products/6-32x1-2-18-8-stainless-steel-button-head-socket-cap-screws

 

[Shimmy]

nice work OP! i've had success using jb weld and then sanding down to finish

 

[BroncoJimbo]

I'm in the same boat. My old Duff's flares are broken, and I always thought I would be able to just order a new set from Duff's when I got around to it. I guess not...
I'd be interested in what you come up with.